Needle and suchlike of knitting machinery



Oct. 21,v 1941, J, MOR-TON v K 2,259,655

v NEEDLE'AND SUGHLIKE 0F KNITTING MACHINERY Filed June ll, V1938 '2 Sheets-Sheet l will!" @W Oct. 2l, 1941. J. MoRToN 252593555 NEEDLE AND ySUCHLIKE OF KNI TTING MACHINERY Filed June ll, 1938 2 Sheets-.Sheet 2 Patented @et 21, 1941 NEEDLE AND SUCHLIKE F KNITTING MACHINERY James Morton, Carlisle, England Application June 11, 193s, serial N6. 215,266 In Great Britain January 19, 1935 s Claims. (ci. `615-86) This application is a continuation-impart of my prior application, Serial No. 58,176, filed J anuary 8, 1936.

This invention relates to the manufacture of knitting-machine needle or the like assemblies (or so-called sections) each consisting of a group of needles or the like secured in a support, such an assembly constituting a single unit. By the term needles or the like is meant knitting needles, hooked or otherwise, thread-guides (sometimes called pillar-ngers), sinkers, and like thread engaging parts of knitting machinesparticularly those known as Warp knitting machines these working parts co-operating to perform the knitting operation and constituting the usual thread engaging parts 'of the machine.

Such needle or the like assemblies are usually arranged side-by-side along some form of carrying bar (such as a guide bar, needle-bar or a sinker-bar) to which the supports are attached, the needles or the like extending in a closely spaced series. The said supports are usually moulded of lead or a lead alloy, in which the needles or the like are embedded while the metal is molten but zinc alloys have also been proposed having a specic gravity as low as 4.6. The supports are removably attached to the carrying bars to facilitate replacement of any assembly having a broken needle or the like. It h'as heretofore been considered essential to employ metal, or a metallic alloy, .for supporting the needles or the like on account of the necessity for securing them rigidly in precise co-relationship and maintaining such co-relationship throughout their life.

A disadvantage associated with the use of metallic supports is that their Weight is a factor requiring to be taken into serious consideration when designing the machines and materially limits the speed of operation and consequently the output of the machines. Experiments made with knitting machinery, particularly with warp knitfirstly, from the action of the thread `on these parts, and secondly, from the accelerations to which the masses of the parts and their supports ting machinery, embodying various improvements directed towards the attainment of speeds of operation and outputs materially higher than are subjected. In the case of thread guides, ad-

' ditional lateral stresses are experienced from the rapid shogging of these elements from side to side. The forces causing the stresses are transmitted to the supports and the actuating mechanisms.

The supports being rigidly secured to the carrying bars at their rear ends, project outwardly .from these bars and, during the operation of the this material capable of running at thev speeds 1 desired. This is due to the high specic gravity of the material, its relatively low fatigue limit and its relatively low modulus of elasticity.

In order to overcome the diliculties hereinbefore experienced I use, in accordance with this invention, supports made of a composition incorporating a light-weight organic plastic in which composition the shanks of the needles or the like are set or embedded by a moulding operation under heat and pressure.V The needles or the like are accurately positioned in correct order and co-relationship in the supports and are positively held therein, the supports being strong and hard and being capable of retaining their strength and hardness under normal working conditions so that they can be used eiectively in machines designed to-run at high speeds.

It might be objected that supports made of light-weight material embodying an organic plastic would be liable to fracture or distortion under the action of rapidly alternating stresses such as set up in a knitting machine; but it has now been determined, by careful experimental tests, that for organic plastic compositions, such as the phenolic resincompositions, the important ratio between the fatigue limit and specific gravity is not only high enough for knitting machines,

but it is very much in excess of the same ratio applicable to theusual lead alloy supports. This is a most surprising and unexpected result and positions incorporating an organic plastic can be used with the greatest conidence in knitting machines designed to run at very high speeds.

The means provided for locating and maintaining the needles or the like in correct order and co-relationship preparatory to and during the moulding operation, consist of accurately spaced serrations or rack members or a light frame in, or adaptedto fit in, the mould, in which serrations, members, or frame, the needles or the like are arranged," the plastic bomposition being supplied as a moulding powder to the mould interior so as closely to surround the shanks of the needles or the like and. when the material is set, under heat and pressure, to hold them permanently and securely in position. The said serrations or serrated members may be provided not onlyv internally but also externally 4of `the mould.

Supports. made in accordance with this invention of a composition consisting of about 50% wood flour illler, about 50% of resin (phenolformaldehyde) as a binder together with such an amount of lubricant (stearic acid) as made the composition free flowing when in the mould,

have been tested in high speed knitting machines and have given very good results. The composition, which is supplied to the mould in the form of a line powder, flows closely round and between the shanks of the closely placed needles or the like and, when set under .heat and pressure, fixes them all firmly in position. There may be a small amount'of accelerator included in the composition. The composition is subjected in the mould to a pressure of about 3000 lbs. to the square inch and a temperature, inside the mould, of from 300 to 350 F.

It is important the composition should be free flowing as it has been found, if the moulding powder is not free iiowing. that the needles or the like are not properly held and are apt sub- .I

sequently to work'loose in the support.

The'moulding is performed in known manner and the operation is carried on for about iive minutes from the time the ram of the moulding machine comes down.

Supports made of a phenolicresinoid composition as aforesaid, are found, when thoroughly tested, to have an extraordinarily high fatigue limit which it is essential they should have so as to withstand the bending stresses set up during the running of the machine. Samples of the supports when tested in a Woehler type fatigue testing machine gave the remarkable endurance under bending stresses for 2.0 million cycles at.

11.65 kg./mm.2 without breaking.- This endurance is more than twice as high as for goo`d leadbase alloys.

In the preferred method of manufacturing a needle or like assembly, and when a phenolic resinoid composition is used for the support, the needles or the like are first arranged inat least one group in a mould provided with serrations and are accurately held in place thereby, then the moulding powder, in fine condition, is charged into the mould and closely pressed round the sh'anks of the needles or the like, then the mould is closed and placed in a steam or electrically heated press and, finally, subjected to the consequently it is obvious supports made of combedded therein ready to be utilized as a section in a knitting machine.

By this method of manufacture, the needles or the like are positively held in correct position and relationship by the serrations of the'mould while the composition attaches itself to and supports them so that when the moulding operation is nished the needles or the like are held very securely in place and project regularly and evenly from the support.

Each support may be moulded with two holes permitting it to be removably attached by screws, or otherwise, to its carrying bar or the like.

It is to be understood that the expression a light-Weight organic plastic composition as used herein is intended to cover such mouldable synthetic resinous compositions as are thermo-plastic and thermo-,setting but it is not coniined thereto as other well known organic plastic compositions which are thermo-plastic and of a speciiic gravity appreciably less than the aforesaid metallic alloys and which, when moulded under heat and pressure, will be strong and set hard and will retain their strength and hardness under normal working conditions, can be used.

Of course as required for strength and lightness suitable light-weight fillers would be chosen for the moulding compositions, a variety of such fillers being obtainable. It has been found that wood flour or flaked fabric gives good results.

The invention will now be described simply by way of example and with reference to the accompanying drawings, as applied to needles and like working parts of warp knitting machines. On the drawings- Fig. 1 is an elevation of an assembly comprising a group of thread-guides and their support.

Fig. 2 is a section on the line II--II of Fig. l.

Fig. 3 is a plan of a mould with parts thereof removed to expose thread-guides embedded in the support, and Fig. 4 is a corresponding sectional fragmentary plan drawn to an enlarged scale.

thread-guides are located in the mould.

Figs. 7, 8, 9 and.10 are sectional perspective views of assemblies comprising groups of latch knitting-needles, sinkers, plush-needles (-i. e. pileforming needles) and bearded knitting-needles,

respectively, and their supports.

required heat and pressure as to convert the` Fig. 11 is a diagrammatic sectional elevation showing co-operating warp-knitting-machine parts respectively mounted in groups in supports, and Fig. 12 is a fragmentary view in the direction oi' the arrow of Fig. 11.

Fig. 13 is a perspective view showing knitting needles held together by cross metallic members.

Fig. 14 is a front view of the same.

Referring to Figs. 1 and 2, the assembly therein shown consists of a group of ,threadguides I0 each formed with a thread-guiding eye or hole Il and each including a stem I2, the guides being arranged side-by-side and being precisely equi-spaced. The support 'consists of a thin block I3 of resinoid from one side of which the guides I0 all project to the same extent. The support I3 is formed with a shoulder I4 and ange I5 having screw holes I6 and is thereby adapted for removable attachment in the usual marmerv to a guide-bar (not shown in this view) to which a number of side-by-side guideholding supports similar to the support |3 would be likewise attached.

In Figs. 3 to 6 a suitable form of mould has been shown which is adapted to mould at one 5 operation resinoid supports for two separate groups of thread-guides I0. The mould structure includes an outer shell 2 0,v vinto which the mould proper ts. The chief elements constituting the mould proper area lower die 2| and duplicate upper dies 22, these elements being separable. Core pins 23 driven tightly 'into holes'in the lower die 2| and registrable with holes in the upper dies 22 serve to form the screw-holes 6.

The thread-guides |0 are spaced apart by series of internal serrations 24 provided at both sides of the die 2|. The thread-guides are additionally supported` by a plain external restface 25 and an external serrated rest 2li-on each of two members 2l inserted into the die 2|. The members 2l are spaced apart by a distancepiece 20 held by a screw 28 to the -die 2|. A pin 30 fitted neatly through the thread-guiding' eyes of each group of thread guides and adapted to seat itself on the external serrations 26 serves to maintain the heads of said guides in precise alignment. The members '2land distance-pieces 28 co-operate with an upper clamp 3| which holds the heads of the guides securely in place.

The serrations are accurately made so as to i .ensure that the needles or the like shall be held in correct relationship during the moulding operation.

In the use of the mould, the lower die 2| with the members 2l and distance-piece 28 thereon is tted into the shell 20. The thread-guides il! are arranged in two groups, with the pins 30 threaded through the eyes of the guides of 40 the respective groups, the guides being accurate-v ly disposed between and laterally supported by the serrations 24 and'26 and also `supported by the faces 25. The resinoid composition in the form of a moulding powder is carefully packed upon both sides of the die, the thread-guides i0 thus becoming embedded in the powder. The dies 22 and the clamp 3| are placed in position. The completely assembled mould is put into af known form of moulding press, and pressure and.

heat are applied so as to convert the composition into the required hardness. After the com- Y position has been' subjected to the required cooking,"the mould is removed from the moulding press and dismantled and the pins 23 55 are withdrawn from the thread-guides, whereupon the newly formed supports I3, with the stems |2 of the thread-guides securely and permanently embedded therein,y are removed.'

The provision of the serration 24 results in 60 the formation of an open slot 32 in each support I3, said slot exposing a short portion of each y stem I2. The eiiect. however of this slot is'neE- ligible as regards the security and rigidity with which the thread-guides are held in place. 35

If desired, serrations similar to the serrations 24 might also be provided in the faces 25.

If desired. a series of double moulds, each similar to the mould proper abovev described, may be provided so that several assemblies may be produced at one moulding operation.

If desired, instead of forming serrations integral with the elements of the mould as in the construction illustrated; light metallic or other frame members in which the thread-guides are port `while holding the manner.

y needles 60.'

located may be inserted into the mould vand embedded along with the thread-guides in the composition.

In Figs. 13 and 14 two cross members I0b and I I0c are shown. These may be of suitable metal and are adapted to hold the shanks of the needles 10 (or other knitting elements) in spaced position when inserted vin the-mould so that when the support is being m'ulded, the ele; ments will be in correct position. and alignment in the support. These cross membersalso serve as ametallic reinforcement tothe nished'supneedle Shanks securely therein. g

If desired, reinforcing material may be incorporated in the support. For example, such-reinforcing material 'may comprise a strip of fabric or a thin metallic or 'other member-if desired,

serrated-arranged across the shanks and in engagement therewith.

With reference to Figs. '7,8` andA 9, the working parts therein shown may be incorporated in.

the same warp-knitting machine to work .in combination with the thread-guides.

Figi 'l shows members of a group of latch.

knitting-needles 4 0 whose shanks 4| are.secure ly embedded in a composite support 42 remov-.

which in the construction shown are embedded at opposite ends in a 'main support 5| and an auxiliary support 52.

This auxiliary support may, if desired, be dispensed with. These sinkers 50 pass between the knitting needles to control the loops formed in the threads being knitted and hold down the fabricV in the usual The main support 5 is' removably attachable, side-by-side with other similar supports, to a sinker-bar (not shown).

Fig. 9 shows members of a group oi'plush- 'warp knitting' machines adapted to form pile loops in the fa-bcs'knitted by them, these pile loops extending from the knitted chains produced by the individual knitting-needles. The shanks 6| of these plush-needles ar embedded in a support 62 securable to aplush-bar (not shown) corresponding to the needle-bar l43.

Referring to Fig. 10, the knitting-needles '|0 therein shown are bearded needles.' Such needles constitute a well known alternative tothe latch needlesshown in Fig. '7.

The thread engaging parts above described with reference to Figs. 'I to l()y are all assembled as groups in their supports in substantially the same manner as already described with reference to Figs. l to 6, the moulds employed being mbdi- I fied in so far as necessary to suit the dimensional and other differences between the diiferent parts.

In the case of the knitting needles 40 and 10, a

positioning pin corresponding to the pin 30 can be threaded through the hooks 40a and 10a of each group of needles; and in the case-of the sinkers 50, a positioning pinA may be placed in the recesses 50*I in the sinkers of eachgro'up.

Fig.v 1l shows a cooperating set of Warpknitting-machine thread engaging parts comprising a row of latch-knitting needles 80, two' rows of thread-guides' 8|, A82, a row of plushneedles 83 and a row of sinkers 84, only one Such needles can be provided inf group are embedded in a support. The supports of the parts 88 to 84, one of each of which supprojections which would help to lock the shanks in the plastic composition.

I have particularly referred to the use of organic plastic compositions with a phenol-formaldehyde binder but I may use other compositions with, say, a cresol-formaldehyde binder or a urea-formaldehyde binder, these compositions several groups of needles 80 constituting a single series. The supports 86-89 of the other parts are similarly secured 9l-94.

The sinkers 8l in the construction illustrated to their respective -bars are adapted to introduce, for incorporation as wefts in the fabric 95 being knitted, cross-threads supplied successively to the sinkerrecesses, one such cross-thread being indicated at 96. These sinkers are mounted in their supports in the manner already described with reference to Figs. l to 6.

The thread-guides 8l lead warp threads, one being indicated by, 91, to the knitting-needles; and the thread-guides 82 lead pile warp threads, one being indicated by 98, to the knitting-needles andthe plush-needles.

In the operation of the knitting-machine parts shown, the needle-bar 90 receives a vertical reciprocatory motion; the guide-bars 9|, 92 receive a compound motion during which the guides lap their threads around the needle hooks; the plushbar 93 receives `a vertical reciprocatory motion during which the plush-needles, when raised, are looped with pile threads 98 by the guides 82 and, when lowered, cast off the loops;

and the sinken-bar 94 receives a horizontal reciprocatory motion during which the sinkers receive land transfer. to the needles a cross-thread In the construction shown in Fig. 11 twoguide bars are shown. There may however be more than two guide-bars', some warp-knitting machines having as many as six, and some even chines; but, if desired, the Shanks of theneedles or the like may be formedl with overturned end being thermo-plastic and thermo-setting; -but I may also use, in certain cases, thermo-plastic lcompositions containing organic derivatives of cellulose such as cellulose-acetate or benzyl cellulose; or I may use a composition containing an organic derivative of rubber, such as ebonite. The s-pecic gravity of the new light weight supports incorporating organic plastics such as the phenolic resins, organic derivatives of cellulose, or rubber derivatives is generally of the order of 1.3 to 2 in contrast with previously proposed supportsmade of metallic alloys having specific gravities from 4 to 6.

The term .thread wherever-used hereinl is to be understood as including knitting yarn and lbre.

I claim:

l. A support for an assembly of thread engaging parts of knitting machines made of a composition incorporating a lightweight organic plastic and' also incorporating a metallic reinforcement adapted to hold the shanks of the thread engaging parts in position in the support.

2. A support for an assembly of thread engaging Aparts of a knitting machine made of a composition incorporating a lightweight organic plastic and moulded under heat and pressure, the support having a metallic. member incorporated therein whichl is adapted to hold the shanks of the thread engaging parts in correct position and alignment in the support.

3. A support wherein are embedded the shanks of an assembly of thread-engaging parts adapted to work at high speed in a warp knitting machine Ain operation-of which said support is subjected to alternating bending stresses, such support being acomposite moulding which incorporates a phenol-formaldehyde resin and a light weight Afiller and which is bothlight. in weight and highly resistant to fatigue under such-stresses. JAMES MORTON. 

